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December 26, 2012

FULL WAVE regulator schematic

A full wave regulator is a type of regulator mostly found on small motorcycle that can enhance the
charging system of motorcycle battery. It can be bought in a four pin or in a five pin configuration as
shown on the left. It is also being used widely by enthusiast that convert their single phase half wave
generator onto a full wave by altering the stator windings.

Wondering what is inside this kind of regulator and how it differs from those commonly used HALF
wave regulator, you are in luck for i have the time and resources to open up this donor regulator. it took
me hours of heating up, scraping the coating to expose the main board and parts.

Here it is.
with the help of a portable blow torch, soldering iron, a small flat screwdriver, and a bit of patience, I
carefully removed the top coating of this regulator exposing the bottom of the PCB. and noticed the
smd (surface mount devices). Seeing that makes me more careful of not scrapping them from their
location.

Patience is the key when doing this kind of hobby.

HOURS later,
Have to desolder first all components to pull out the pcb.

 The bridge rectifier that needs to be heatsinked.

 the epoxy residue..(too tough to scrape)

 top view

 side view

back view
And the schematic of this board

By comparing this to my previous post

Single Phase Shunt Regulator (full wave)

They are almost identical, but as i have said, the regulator above is a five wire type, the schematic
shown on left is a four pin type. The difference, the circuit within the link is always connected to the
battery thus leakage is present. while as this regulator has a wire (BLACK) that is connected after the
ignition switch and not directly to the battery.

It was used for one reason:

1. when ignition off, monitoring circuit of the schematic is disabled, no current will be taken from the
battery when stored, or park.

We have a saying " its better to have more than to have enough" This particular five wire regulators can
be used on four wire type. just connect the black and red together..

By looking at the schematic, and comparing it to my previous post of voltage regulators, it is almost
identical, with the design, and only component values are different. C1, R1, Q1, D1, and R3
compromising the sensing and regulating circuit, whereas D2,D3, Q2 and Q3 are the shunting
components of the stator winding.
D4 to D7 are your rectifiers that converts the AC coming from the stator to DC for charging your
battery. With the values as shown, the output of this regulator is 14.4 at 5000rpm. You can modify this
circuit for your intended application, to output 15 volts rather than 14.4 for quick charging of your
battery when there are too much load on your system, by altering D1, to 13 volts rather than 12.6 volts..
This system is Stator dependent...meaning, this can't output more power on what your stator can give,
all charging system power rely on your stator max output...

Note: further again..the generator to be used here do not touch the ground or not connected to any
ground. 

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Nathaniel Berdan

http://mastercircuits.blogspot.com/

my hobby of course
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